Copolyesterimides of poly(alkylene naphthalate)s having high glass transition temperature and film made therefrom

ABSTRACT

A copolyester comprising repeating units derived from an aliphatic glycol, naphthalene-dicarboxylic acid, and the monomer of formula (I) wherein n=2, 3 or 4, and films, fibres, moulding compositions and moulded articles made therefrom.

The present invention is concerned with novel polyesters and films made therefrom, and methods for their synthesis. In particular, the present invention is concerned with novel copolymers of poly(alkylene naphthalate)s, particularly poly(ethylene naphthalate) (PEN), which exhibit improved heat-resistance and thermo-mechanical stability.

The glass transition temperature (T_(g)), crystalline melting point (T_(m)) and degree of crystallinity are key parameters in determining the thermo-mechanical properties of polyesters. Previous studies have succeeded in increasing the T_(g) of thermoplastic polymers, primarily homopolymers, but this has typically been accompanied by a corresponding increase in the T_(m). Such increases in T_(m) can be disadvantageous because a thermoplastic polymer should also remain melt-processable (for instance in an extruder), and should preferably remain so under economic conditions (for instance, below about 320° C., preferably below about 300° C., which allows the use of conventional extrusion equipment). At higher processing temperatures, polymer extrusion requires expensive specialist equipment and a great deal of energy, and typically also results in degradation products. The melt-processing temperature should be well below (for instance, at least about 20° C. below) the decomposition temperature of the polymer. In some cases, comonomers have been introduced into polymers in order to increase T_(g) while retaining T_(m), but also resulting in convergence of the decomposition temperature and the T_(m), which leads to the production of degradation products in the melt.

Many attempts have also been made to enhance the glass transition temperature of polyesters by the introduction of more rigid comonomers. However, such comonomers also disrupt the packing of the polymer chains in the crystal lattice, so that while the T_(g) increases, the T_(m) and degree of crystallinity typically both decrease as the proportion of comonomer increases, leading ultimately to amorphous materials. In order to fabricate articles from polymeric materials, it is often critical that the polymer exhibit crystallinity to achieve articles with acceptable thermo-mechanical properties.

PEN is a semi-crystalline copolymer having a higher glass transition temperature (T_(g)=120° C.) relative to poly(ethylene terephthalate) (PET; T_(g)=78° C.), although their crystalline melting points do not differ greatly (T_(m)=268° C. for PEN and 260° C. for PET). The thermo-mechanical stability of PEN is significantly greater than that of PET. Many of the attempts made to enhance T_(g) by the introduction of more rigid comonomers have focussed on PET, which is significantly cheaper than PEN. There are no commercially available semi-crystalline polyesters with a T_(g) higher than PEN. Polyether ether ketone (PEEK) is one of the few examples of a high T_(g) (approximately 143-146° C.) semi-crystalline thermoplastic polymer, and has been used successfully in engineering and biomedical applications. However, PEEK is suitable only for certain types of articles; for instance, it is not suitable for the manufacture of biaxially oriented films. PEEK is also very expensive and has a high crystalline melting point (approximately 350° C.).

An object of the present invention is to provide polyesters which exhibit improved heat-resistance and thermo-mechanical stability. A further object of the present invention is to provide a thermoplastic polymer with high or increased T_(g) but without increasing T_(m) to a point where the polymer is no longer melt-processable under economic conditions (i.e. the polymer should remain melt-processable below about 320° C., preferably below about 300° C.). A further object of the present invention is to provide semi-crystalline polyesters which exhibit high T_(g) as well as high T_(m). A further object of the present invention is to increase the T_(g) of a polyester without significantly decreasing its T_(m) and/or its degree of crystallinity, and preferably without significantly decreasing its decomposition temperature.

As used herein, the term “without significantly decreasing the T_(m)” means that the T_(m) decreases by no more than 10%, preferably no more than 5%.

As used herein, the term “without significantly decreasing the degree of crystallinity”, means that the polyester retains a degree of crystallinity which is commercially useful, preferably in the range of from about 10% to about 60%, preferably from about 20 to about 50%.

A further object of the present invention is to provide a copolyester having a T_(g) which is higher than the corresponding base polyester, without significantly decreasing its T_(m) and/or its degree of crystallinity and preferably without significantly decreasing its decomposition temperature.

A further object of the present invention is to provide a comonomer suitable for partial substitution of a monomer in a conventional polyester which increases the T_(g) of said polyester without significantly decreasing its T_(m) and/or its degree of crystallinity, and preferably without significantly decreasing its decomposition temperature.

While the objects of the invention do not exclude an increase in T_(m), any increase in T_(m) must not be so large that melt-processing becomes uneconomical and that the T_(m) and decomposition temperature converge.

As used herein, the term “copolyester” refers to a polymer which comprises ester linkages and which is derived from three or more types of comonomers. As used herein, the term “corresponding base polyester” refers to a polymer which comprises ester linkages and which is derived from two types of comonomers comprising ester-forming functionalities, and which serves as a comparator for a copolyester which is derived from comonomers comprising the comonomers of the corresponding base polyester. A comonomer comprising ester-forming functionalities preferably possesses two ester-forming functionalities.

As used herein, the term “semi-crystalline” is intended to mean a degree of crystallinity of at least about 5% measured according to the test described herein, preferably at least about 10%, preferably at least about 15%, and preferably at least about 20%.

Accordingly, the present invention provides a copolyester comprising repeating units derived from an aliphatic glycol, naphthalene-dicarboxylic acid, and the monomer of formula (I):

wherein n=2, 3 or 4, and preferably wherein n=2.

Surprisingly, the present inventors have now found that incorporation of the specific co-monomer (I) into a naphthalate polyester not only increases the T_(g) substantially but does so without significantly decreasing the T_(m), and without significant detriment to the degree of crystallinity. The copolyesters according to the present invention are thermoplastic. Copolyesters described herein exhibit semi-crystalline properties. The copolyesters according to the present invention can be readily obtained at high molecular weight. The copolyesters according to the present invention can be melt-processed below 320° C. (preferably below 300° C.) into tough, high strength articles. The copolyesters are also referred to herein as co(polyester-imide)s.

The comonomer (I) constitutes a proportion of the glycol fraction of the copolyester. In a preferred embodiment, the comonomer (I) is present in a range of from about 1 to about 50 mol % of the glycol fraction of the copolyester, preferably from about 1 to about 40 mol %, preferably from about 1 to about 30 mol %, preferably at least about 5 mol %, more preferably at least about 8 mol %, preferably no more than about 25 mol %, preferably no more than about 22 mol %, and in one embodiment in the range of from about 10 to about 20 mol %. In a further preferred embodiment, comonomer (I) is present in a range of from about 5 to about 25 mol % of the glycol fraction of the copolyester, preferably from about 5 to about 20 mol %, preferably from about 5 to about 15 mol %. The inventors have observed that even at low molar fractions of the comonomer (I), small but valuable increases in T_(g) are observed. For instance, a copolyester based on PEN comprising only 5 mol % comonomer (I) where n=2 exhibits a rise of about 9° C. in T_(g). At the higher molar fractions of comonomer (I) noted above, T_(g) is advantageously increased further, and this is accompanied by higher values of T_(m) and degree of crystallinity, which can confer useful properties, despite the generally higher costs in melt-processing polymers above about 320° C. noted above.

The naphthalene dicarboxylic acid component of the copolyester can be selected from 2,5-, 2,6- or 2,7-naphthalene dicarboxylic acid, and is preferably 2,6-naphthalene dicarboxylic acid.

The aliphatic glycol is preferably selected from C₂, C₃ or C₄ aliphatic diols, more preferably from ethylene glycol, 1,3-propanediol and 1,4-butanediol, more preferably from ethylene glycol and 1,4-butanediol, and is most preferably ethylene glycol. The number of carbon atoms in the aliphatic glycol may be the same or different as the number (n) in the comonomer (I), but it is most preferably the same in order to retain crystallinity, particularly in order to retain crystallinity with increasing amounts of comonomer. Thus, the aliphatic glycol preferably has the formula HO(CH₂)_(m)OH, where m=n.

In one embodiment, the aliphatic glycol is 1,4-butanediol and n=4. In a preferred embodiment, the aliphatic glycol is ethylene glycol and n=2.

Copolyesters wherein the acid component is selected from 2,6-naphthalene dicarboxylic acid can be described by formula (II) below:

wherein:

n is as defined for formula (I);

the group X is the carbon chain of said aliphatic glycol;

and p and q are the molar fractions of the aliphatic glycol-containing repeating ester units and the monomer (I)-containing repeating ester units, respectively, i.e. q is from 1 to 50 (and preferably at least 8), and p=100−q.

In one embodiment, the copolyester may contain more than one type of aliphatic glycol, and/or more than one type of naphthalene-dicarboxylic acid, and/or more than one type of monomer of formula (I). Preferably, however, the copolyester comprises a single type of aliphatic glycol. Preferably, the copolyester comprises a single type of naphthalene-dicarboxylic acid. Preferably, the copolyester comprises a single type of monomer of formula (I). Preferably, the copolyester comprises a single type of aliphatic glycol, and a single type of naphthalene-dicarboxylic acid, and a single type of monomer of formula (I).

The copolyesters may contain minor amounts of other glycols and in a preferred embodiment such other glycols constitute no more than 10 mol %, preferably no more than 5 mol %, preferably no more than 1 mol % of the total glycol fraction, but in order to maximise performance it is preferred that the glycol fraction consists of comonomer (I) and said aliphatic glycol(s) described above.

The copolyesters of the present invention may contain minor amounts (preferably no more than 10 mol %, preferably no more than 5 mol %, preferably no more than 1 mol % of the total acid fraction) of one or more other dicarboxylic acids (preferably aromatic dicarboxylic acids), for instance including terephthalic acid, isophthalic acid, 1,4-naphthalenedicarboxylic acid, 4,4′-diphenyldicarboxylic acid, 1,4-cyclohexane dimethanol and 1,6-hexanediol. Preferably, however, the acid fraction consists of naphthalene-dicarboxylic acid.

Thus, the copolyester of the present invention preferably contains only aliphatic glycol, naphthalene-dicarboxylic acid and the monomer of formula (I) defined hereinabove.

The copolyesters of the present invention can be synthesised according to conventional techniques for the manufacture of polyester materials by condensation or ester interchange, typically at temperatures up to about 310° C. Polycondensation may include a solid phase polymerisation stage. The solid phase polymerisation may be carried out in a fluidised bed, e.g. fluidised with nitrogen, or in a vacuum fluidised bed, using a rotary vacuum drier. Suitable solid phase polymerisation techniques are disclosed in, for example, EP-A-0419400 the disclosure of which is incorporated herein by reference. In one embodiment, the copolyester is prepared using germanium-based catalysts which provide a polymeric material having a reduced level of contaminants such as catalyst residues, undesirable inorganic deposits and other by-products of polymer manufacture. In one embodiment, the aliphatic glycol is reacted with the naphthalene dicarboxylic acid to form a bis(hydroxyalkyl)-naphthalate, which is then reacted with the monomer (I) in the desired molar ratios under conditions of elevated temperature and pressure in the presence of a catalyst, as exemplified in Scheme (1) hereinbelow.

According to a further aspect of the present invention, there is provided the compound of formula (I):

wherein n=2, 3 or 4, and preferably n=2.

According to a further aspect of the present invention, there is provided a method of synthesis for the compound of formula (I) comprising the step of contacting 4,4′-biphthalic anhydride (also known as 3,3′,4,4′-biphenyl tetracarboxylic dianhydride (BPDA)) and an alkanolamine of formula HO(CH₂)_(n)NH₂ (wherein n=2, 3 or 4) in a solvent and heating the mixture (preferably to a temperature in the range of from about 110 to about 140° C., for a period in the range of from about 6 to about 15 hours).

Suitable solvents include mixtures of DMAc and toluene. Water by-product is suitably removed from the reaction zone during the course of the reaction, for instance by azeotropic distillation. Further steps in the synthetic and isolation procedure typically comprise:

-   -   (i) after the heating step, adding the hot reaction mixture to         an approximately equal volume of water, which is then stirred,         filtered, washed (for instance with water and then with         methanol) and dried;     -   (ii) boiling the dried solid material in water to remove         residual solvent, then filtering hot, washing with methanol, and         dried.

The copolyesters of the present invention are particularly suitable for use in applications involving exposure to high temperatures and applications which demand high thermo-mechanical performance. The copolyesters may be used to fabricate items in applications in which PEEK has been used, including mechanical components (such as bearings, piston parts, pumps and compressor plate valves); cable insulation; components for ultra-high vacuum applications; advanced biomaterials (including medical implants); and other applications in the aerospace, automotive, teletronic, and chemical process industries. The advantage of the copolyesters of the present invention over PEEK is that they exhibit comparable T_(g) values, but with a T_(m) which is significantly lower. The copolyesters of the present invention can be used in fibre form or in moulding compositions.

According to a further aspect of the invention, there is provided a fibre or moulding composition or moulded article comprising a copolyester comprising repeating units derived from an aliphatic glycol, naphthalene-dicarboxylic acid, and the monomer of formula (I) defined hereinabove. The fibre, moulding composition or moulded article may be produced according to conventional techniques in the art.

The copolyesters of the present invention are also suitable for film manufacture. Biaxially oriented films in particular are useful as base films for magnetic recording media, particularly magnetic recording media required to exhibit reduced track deviation in order to permit narrow but stable track pitch and allow recording of higher density or capacity of information, for instance magnetic recording media suitable as server back-up/data storage, such as the LTO (Linear Tape Open) format. The copolyesters of the present invention are also suitable for the manufacture of film (preferably biaxially oriented film) for use in electronic and opto-electronic devices (particularly wherein the film is required to be flexible) where thermo-mechanically stable backplanes are critical during fabrication of the finished product, for instance in the manufacture of electroluminescent (EL) display devices (particularly organic light emitting display (OLED) devices), electrophoretic displays (e-paper), photovoltaic (PV) cells and semiconductor devices (such as organic field effect transistors, thin film transistors and integrated circuits generally), particularly flexible such devices.

According to a further aspect of the present invention, there is provided a film comprising a copolyester comprising repeating units derived from an aliphatic glycol, naphthalene-dicarboxylic acid, and the monomer of formula (I) defined hereinabove. The film is preferably an oriented film, preferably a biaxially oriented film. Said copolyester is preferably the major component of the film, and makes up at least 50%, preferably at least 65%, preferably at least 80%, preferably at least 90%, and preferably at least 95% by weight of the total weight of the film. Said copolyester is suitably the only polyester used in the film.

When the copolyester of the present invention is formed into a film or other article, the preferred amounts of comonomer (I) in the copolyester is in the preferred ranges described above for the copolyester itself, and preferably in the range of from about 5 to about 25 mol % of the glycol fraction of the copolyester, preferably from about 5 to about 20 mol %, preferably from about 5 to about 15 mol %.

Formation of the film may be effected by conventional extrusion techniques well-known in the art. In general terms the process comprises the steps of extruding a layer of molten polymer at a temperature within an appropriate temperature range, for instance in a range of from about 280 to about 300° C., quenching the extrudate and orienting the quenched extrudate. Orientation may be effected by any process known in the art for producing an oriented film, for example a tubular or flat film process. Biaxial orientation is effected by drawing in two mutually perpendicular directions in the plane of the film to achieve a satisfactory combination of mechanical and physical properties. In a tubular process, simultaneous biaxial orientation may be effected by extruding a thermoplastics polyester tube which is subsequently quenched, reheated and then expanded by internal gas pressure to induce transverse orientation, and withdrawn at a rate which will induce longitudinal orientation. In the preferred flat film process, the film-forming polyester is extruded through a slot die and rapidly quenched upon a chilled casting drum to ensure that the polyester is quenched to the amorphous state. Orientation is then effected by stretching the quenched extrudate in at least one direction at a temperature above the glass transition temperature of the polyester. Sequential orientation may be effected by stretching a flat, quenched extrudate firstly in one direction, usually the longitudinal direction, i.e. the forward direction through the film stretching machine, and then in the transverse direction. Forward stretching of the extrudate is conveniently effected over a set of rotating rolls or between two pairs of nip rolls, transverse stretching then being effected in a stenter apparatus. Stretching is generally effected so that the dimension of the oriented film is from 2 to 5, more preferably 2.5 to 4.5 times its original dimension in the or each direction of stretching. Typically, stretching is effected at temperatures higher than the T_(g) of the polyester, preferably about 15° C. higher than the T_(g). Greater draw ratios (for example, up to about 8 times) may be used if orientation in only one direction is required. It is not necessary to stretch equally in the machine and transverse directions although this is preferred if balanced properties are desired.

A stretched film may be, and preferably is, dimensionally stabilised by heat-setting under dimensional support at a temperature above the glass transition temperature of the polyester but below the melting temperature thereof, to induce the desired crystallisation of the polyester. During the heat-setting, a small amount of dimensional relaxation may be performed in the transverse direction (TD) by a procedure known as “toe-in”. Toe-in can involve dimensional shrinkage of the order 2 to 4% but an analogous dimensional relaxation in the process or machine direction (MD) is difficult to achieve since low line tensions are required and film control and winding becomes problematic. The actual heat-set temperature and time will vary depending on the composition of the film and its desired final thermal shrinkage but should not be selected so as to substantially degrade the toughness properties of the film such as tear resistance. Within these constraints, a heat set temperature of about 180 to 245° C. is generally desirable. After heat-setting the film is typically quenched rapidly in order induce the desired crystallinity of the polyester.

In one embodiment, the film may be further stabilized through use of an in-line relaxation stage. Alternatively the relaxation treatment can be performed off-line. In this additional step, the film is heated at a temperature lower than that of the heat-setting stage, and with a much reduced MD and TD tension. The tension experienced by the film is a low tension and typically less than 5 kg/m, preferably less than 3.5 kg/m, more preferably in the range of from 1 to about 2.5 kg/m, and typically in the range of 1.5 to 2 kg/m of film width. For a relaxation process which controls the film speed, the reduction in film speed (and therefore the strain relaxation) is typically in the range 0 to 2.5%, preferably 0.5 to 2.0%. There is no increase in the transverse dimension of the film during the heat-stabilisation step. The temperature to be used for the heat stabilisation step can vary depending on the desired combination of properties from the final film, with a higher temperature giving better, i.e. lower, residual shrinkage properties. A temperature of 135 to 250° C. is generally desirable, preferably 150 to 230° C., more preferably 170 to 200° C. The duration of heating will depend on the temperature used but is typically in the range of 10 to 40 seconds, with a duration of 20 to 30 seconds being preferred. This heat stabilisation process can be carried out by a variety of methods, including flat and vertical configurations and either “off-line” as a separate process step or “in-line” as a continuation of the film manufacturing process. Film thus processed will exhibit a smaller thermal shrinkage than that produced in the absence of such post heat-setting relaxation.

The film may further comprise any other additive conventionally employed in the manufacture of polyester films. Thus, agents such as anti-oxidants, UV-absorbers, hydrolysis stabilisers, cross-linking agents, dyes, fillers, pigments, voiding agents, lubricants, radical scavengers, thermal stabilisers, flame retardants and inhibitors, anti-blocking agents, surface active agents, slip aids, gloss improvers, prodegradents, viscosity modifiers and dispersion stabilisers may be incorporated as appropriate. Such components may be introduced into the polymer in a conventional manner. For example, by mixing with the monomeric reactants from which the film-forming polymer is derived, or the components may be mixed with the polymer by tumble or dry blending or by compounding in an extruder, followed by cooling and, usually, comminution into granules or chips. Masterbatching technology may also be employed. The film may, in particular, comprise a particulate filler which can improve handling and windability during manufacture, and can be used to modulate optical properties. The particulate filler may, for example, be a particulate inorganic filler (e.g. metal or metalloid oxides, such as alumina, titania, talc and silica (especially precipitated or diatomaceous silica and silica gels), calcined china clay and alkaline metal salts, such as the carbonates and sulphates of calcium and barium).

The thickness of the film can be in the range of from about 1 to about 500 μm, typically no more than about 250 μm, and typically no more than about 150 μm. Particularly where the film of the present invention is for use in magnetic recording media, the thickness of the multilayer film is suitably in the range of from about 1 to about 10 μm, more preferably from about 2 to about 10 μm, more preferably from about 2 to about 7 μm, more preferably from about 3 to about 7 μm, and in one embodiment from about 4 to about 6 μm. Where the film is to be used as a layer in electronic and display devices as described herein, the thickness of the multilayer film is typically in the range of from about 5 to about 350 μm, preferably no more than about 250 μm, and in one embodiment no more than about 100 μm, and in a further embodiment no more than about 50 μm, and typically at least 12 μm, more typically at least about 20 μm.

According to a further aspect of the invention, there is provided an electronic or opto-electronic device comprising the film (particularly the biaxially oriented film) described herein, particularly electronic or opto-electronic devices such as electroluminescent (EL) display devices (particularly organic light emitting display (OLED) devices), electrophoretic displays (e-paper), photovoltaic (PV) cells and semiconductor devices (such as organic field effect transistors, thin film transistors and integrated circuits generally), particularly flexible such devices.

According to a further aspect of the invention, there is provided a magnetic recording medium comprising the film (particularly the biaxially oriented film) described herein as a base film and further comprising a magnetic layer on one surface thereof. The magnetic recording medium includes, for example, linear track system data storage tapes such as QIC or DLT, and, SDLT or LTO of a further higher capacity type. The dimensional change of the base film due to the temperature/humidity change is small, and so a magnetic recording medium suitable to high density and high capacity causing less track deviation can be provided even when the track pitch is narrowed in order to ensure the high capacity of the tape.

The following test methods were used to characterise the properties of the novel compounds disclosed herein.

-   (i) Glass transition temperature (T_(g)); temperature of cold     crystallisation (T_(cc)), crystalline melting point (T_(m)) and     degree of crystallinity (X_(c)) were measured by differential     scanning calorimetry (DSC) using a Universal V4.5A machine (TA     Instruments) according to the following test method and otherwise     according to the method described in ASTM E1356-98. The sample was     maintained under an atmosphere of dry nitrogen for the duration of     the scan (approx. 1.5 to 3 hours). The sample (4-6 mg) was heated     from 20° C. to 300° C. at a rate of 20° C./min, held at 300° C. for     5 minutes, and then cooled to 20° C. at a rate of 20° C./min, and     then heated from 20° C. to 350° C. at 10° C./min. The thermal     properties were recorded on the second heating scan.     -   The value of T_(g) was taken as the extrapolated onset         temperature of the glass transition observed on the DSC scan         (heat flow (W/g) against temperature (° C.)), as described in         ASTM E1356-98.     -   The values of T_(cc) and T_(m) were taken from the DSC scan as         the temperature at which peak heat flow was observed in the         respective transitions.     -   The degree of crystallinity (X_(c)) was calculated according to         the equation:

X _(c) =ΔH _(m) /ΔH _(m)°

-   -   wherein:     -   ΔH_(m)=experimental enthalpy of fusion calculated from the         integral of the melting endotherm;     -   ΔH_(m)°=theoretical enthalpy of fusion of the corresponding         poly(alkylene-naphthalate) homopolymer (i.e. without the         co-monomer of formula (I)) at 100% crystallinity. Thus, for         copolyesters of the present invention comprising repeating units         derived from ethylene glycol, naphthalene-dicarboxylic acid and         the co-monomer of formula (I), ΔH_(m)° is the theoretical         enthalpy of fusion of a 100% crystalline PEN polymer (103 J/g)         as defined in the literature (B. Wunderlich, Macromolecular         Physics, Academic Press, New York, (1976)).     -   Herein, the degree of crystallinity is measured for samples         which have been annealed at 200° C. for 2 hours. The annealing         of the sample was conducted during a DSC heating cycle. The full         heating cycle for these crystallinity measurements was as         follows:         -   (i) Heated from 20 to 300° C. at 20° C./min         -   (ii) Held at 300° C. for 5 minutes         -   (iii) Cooled to 20° C. at 20° C./min         -   (iv) Heated to 200° C. at 20° C./min         -   (v) Held at 200° C. for 120 min         -   (vi) Cooled to 20° C.         -   (vii) Heated from 20 to 400° C. at 10° C./min.     -   The thermal properties were recorded on the final heating scan.

-   (ii) Inherent viscosity (η_(inh)) was determined at 25° C. for 0.1%     w/v solutions of the polymer in CHCl₃/TFA (2:1) using a     Schott-Geräte CT-52 auto-viscometer, with capillary No. 53103.     Inherent viscosities were calculated as:

η_(inh)=ln [(t ₂ /t ₁)/c]

-   -   wherein:     -   η_(inh)=Inherent Viscosity (dL/g)     -   t₁=Flow time of solvent (s)     -   t₂=Flow time of the polymer solution (s)     -   c=Concentration of the polymer (g/dL)

The invention is further illustrated by the following examples. It will be appreciated that the examples are for illustrative purposes only and are not intended to limit the invention as described above. Modification of detail may be made without departing from the scope of the invention.

EXAMPLES

A reaction scheme to prepare copolyesters of the present invention is shown in Scheme 1 below.

Example 1 Synthesis of N,N′-bis-(2-hydroxyethyl)-4,4′-biphthalimide (Monomer 1)

4,4′-biphthalic dianhydride (5.65 g, 19.20 mmol), ethanolamine (2.4 ml, 39.37 mmol), DMAc (40 ml) and toluene (35 ml) were charged to a 250 ml round bottom flask and heated to 130° C. overnight. Dean-Stark apparatus was used to azeotropically distill off the water by-product. The hot reaction mixture was then added to water (˜400 ml) upon which a white precipitate formed. This was then stirred for 6 hours, filtered, washed with water (2×40 ml) and MeOH (2×40 ml) and dried in a vacuum oven at 100° C. overnight. Residual solvent was removed as the product was boiled in water (40 ml) for 4 hours then filtered hot, washed with MeOH (2×25 ml), filtered and dried in a vacuum oven at 80° C. overnight. The isolated product was a white powder. (6.21 g, 81%), m.p. (DSC) 286° C., ¹H NMR (400 MHz, DMSO) δ (ppm) 8.22 (m, ΔH_(b+c)), 7.97 (d, J=8.16 Hz, 2H_(a)), 4.85 (t, J=11.96 Hz, 2H_(f)), 3.67 (t, J=11.28 Hz, ΔH_(d)), 3.59 (m, ΔH_(f)), ¹³C NMR (400 MHz, DMSO) 167.48 (C₇₊₈), 144.00 (C₁), 137.17 (C₆), 132.75 (C₄), 131.42 (C₃), 123.53 (C₅), 121.68 (C₂), 57.90 (C₉), 40.42 (C₁₀), IR: 3445, 2944, 1763, 1684, 1384, 1011, 739 cm⁻¹.

Example 2 Synthesis of a Copolymer of PEN Containing 5 mol % of Monomer 1

Bis-(2-hydroxyethyl)-2,6-naphthalate (4.7498 g, 15.62 mmol), N,N′-bis-(2-hydroxyethyl)-4,4′-biphthalimide (0.3128 g, 0.82 mmol) and GeO₂ (5.2 mg, 0.04 mmol) were charged to a Schlenk tube fitted with a rubber sealed stirrer guide and a glass stirrer rod. The reaction mixture was heated to 200° C. over 30 minutes by use of a tube furnace under an inert nitrogen atmosphere. A vacuum of 2.8 torr was gradually applied over 1-2 minutes and a stirring rate of 300 rpm was applied via a mechanical stirrer and the reaction mixture was heated to 300° C. over 10 min. This temperature was maintained for 1.5 hours when the melt became increasingly more viscous. After this time nitrogen was purged through the system, the stirrer was removed and the mixture was allowed to cool. The reaction tube was cut and the glass tubing containing the polymer was broken up. The polymer was dissolved away from the glass and the stirrer in a solution of CHCl₃/TFA (2:1) (˜50 ml) and the glass was filtered off. The brown solution was concentrated in vacuo to ˜10-15 ml and added dropwise into MeOH (˜120 ml). The resulting white polymer beads were filtered, washed with MeOH (2×15 ml) and dried in a vacuum oven overnight. T_(g)=128° C., T_(cc)=220° C., T_(m)=257° C., T_(d)=425° C., ΔH_(m)=35 Jg⁻¹, η_(inh)=0.47 dLg⁻¹. (T_(d) signifies the temperature at which a 10% weight loss was observed). The product was fully soluble in chloroform/trifluoroacetic acid and in hexafluoropropan-2-ol.

Example 3 Synthesis of a Copolymer of PEN Containing 10 mol % of Monomer 1

Bis-(2-hydroxyethyl)-2,6-naphthalate (4.5012 g, 14.79 mmol), N,N′-bis-(2-hydroxyethyl)-4,4′-biphthalimide (0.6253 g, 1.64 mmol) and GeO₂ (5.5 mg, 0.04 mmol) were charged to a Schlenk tube fitted with a rubber sealed stirrer guide and a glass stirrer rod. The reaction mixture was heated to 200° C. over 30 minutes by use of a tube furnace under an inert nitrogen atmosphere. A vacuum of 3.3 torr was gradually applied over 1-2 minutes and a stirring rate of 300 rpm was applied via a mechanical stirrer and the reaction mixture was heated to 300° C. over 10 min. This temperature was maintained for 1.5 hours where the melt became increasingly more viscous. After this time nitrogen was purged through the system, the stirrer was removed and the mixture was allowed to cool. The reaction tube was cut and the glass tubing containing the polymer was broken up. The polymer was dissolved away from the glass and the stirrer in a solution of CHCl₃/TFA (2:1) (˜50 ml) and the glass was filtered off. The brown solution was concentrated in vacuo to ˜10-15 ml and added dropwise into MeOH (˜120 ml). The resulting white polymer beads were filtered, washed with MeOH (2×15 ml) and dried in a vacuum oven overnight. T_(g)=134° C., T_(cc)=227° C., T_(m)=270° C., ΔH_(m)=32 Jg⁻¹, η_(inh)=0.41 dLg⁻¹. The product was fully soluble in chloroform/trifluoroacetic acid and in hexafluoropropan-2-ol.

Example 4 Synthesis of a Copolymer of PEN Containing 15 mol % of Monomer 1

Bis-(2-hydroxyethyl)-2,6-naphthalate (4.2507 g, 13.97 mmol), N,N′-bis-(2-hydroxyethyl)-4,4′-biphthalimide (0.9374 g, 2.46 mmol) and GeO₂ (5.1 mg, 0.04 mmol) were charged to a Schlenk tube fitted with a rubber sealed stirrer guide and a glass stirrer rod. The reaction mixture was heated to 200° C. over 30 minutes by use of a tube furnace under an inert nitrogen atmosphere. A vacuum of 3.8 torr was gradually applied over 1-2 minutes and a stirring rate of 300 rpm was applied via a mechanical stirrer and the reaction mixture was heated to 300° C. over 10 min. This temperature was maintained for 3 hours where the melt became increasingly more viscous. After this time nitrogen was purged through the system, the stirrer was removed and the mixture was allowed to cool. The reaction tube was cut and the glass tubing containing the polymer was broken up. The polymer was dissolved away from the glass and the stirrer in a solution of CHCl₃/TFA (2:1) (˜50 ml) and the glass was filtered off. The brown solution was concentrated in vacuo to ˜10-15 ml and added dropwise into MeOH (˜120 ml). The resulting white polymer beads were filtered, washed with MeOH (2×15 ml) and dried in a vacuum oven overnight. T_(g)=140° C., T_(cc)=234° C., T_(m)=278° C., T_(d)=471° C., ΔH_(m)=33 Jg⁻¹, η_(inh)=0.61 dLg⁻¹. The product was fully soluble in chloroform/trifluoroacetic acid and in hexafluoropropan-2-ol. The product crystallises from the melt.

Example 5 Synthesis of a Copolymer of PEN Containing 20 mol % of Monomer 1

Bis-(2-hydroxyethyl)-2,6-naphthalate (4.0012 g, 13.15 mmol), N,N′-bis-(2-hydroxyethyl)-4,4′-biphthalimide (1.2508 g, 3.29 mmol) and GeO₂ (5.2 mg, 0.04 mmol) were charged to a Schlenk tube fitted with a rubber sealed stirrer guide and a glass stirrer rod. The reaction mixture was heated to 200° C. over 30 minutes by use of a tube furnace under an inert nitrogen atmosphere. A vacuum of 0.7 torr was gradually applied over 1-2 minutes and a stirring rate of 300 rpm was applied via a mechanical stirrer and the reaction mixture was heated to 300° C. over 10 min. This temperature was maintained for 2 hours where the melt became increasingly more viscous. After this time nitrogen was purged through the system, the stirrer was removed and the mixture was allowed to cool. The reaction tube was cut and the glass tubing containing the polymer was broken up. The polymer was dissolved away from the glass and the stirrer in a solution of CHCl₃/TFA (2:1) (˜50 ml) and the glass was filtered off. The brown solution was concentrated in vacuo to ˜10-15 ml and added dropwise into MeOH (˜120 ml). The resulting white polymer beads were filtered, washed with MeOH (2×15 ml) and dried in a vacuum oven overnight. T_(g)=143° C., T_(m)=286° C., ΔH_(m)=26 Jg⁻¹, η_(inh)=0.61 dLg⁻¹. The product was fully soluble in chloroform/trifluoroacetic acid and in hexafluoropropan-2-ol.

Example 6 Synthesis of a Copolymer of PEN Containing 25 mol % of Monomer 1

Bis-(2-hydroxyethyl)-2,6-naphthalate (3.7507 g, 12.32 mmol), N,N′-bis-(2-hydroxyethyl)-4,4′-biphthalimide (1.5625 g, 4.11 mmol) and GeO₂ (5.1 mg, 0.04 mmol) were charged to a Schlenk tube fitted with a rubber sealed stirrer guide and a glass stirrer rod. The reaction mixture was heated to 200° C. over 30 minutes by use of a tube furnace under an inert nitrogen atmosphere. A vacuum of 4.0 torr was gradually applied over 1-2 minutes and a stirring rate of 300 rpm was applied via a mechanical stirrer and the reaction mixture was heated to 300° C. over 10 min. This temperature was maintained for 1.5 hours where the melt became increasingly more viscous. After this time nitrogen was purged through the system, the stirrer was removed and the mixture was allowed to cool. The reaction tube was cut and the glass tubing containing the polymer was broken up. The polymer was dissolved away from the glass and the stirrer in a solution of CHCl₃/TFA (2:1) (˜50 ml) and the glass was filtered off. The brown solution was concentrated in vacuo to ˜10-15 ml and added dropwise into MeOH (˜120 ml). The resulting white polymer beads were filtered, washed with MeOH (2×15 ml) and dried in a vacuum oven overnight. T_(g)=147° C., T_(m)=287° C., ΔH_(m)=44 Jg⁻¹, η_(inh)=0.54 dLg⁻¹. The product was fully soluble in chloroform/trifluoroacetic acid and in hexafluoropropan-2-ol.

The experimental data for the Examples are summarised in Table 1 below.

TABLE 1 T_(g) T_(cc) T_(m) ΔH_(m) Xc Viscosity Sample Polymer (° C.) (° C.) (° C.) (J/g) (%) (gdL⁻¹) Control PEN 119 191 267 36 35 0.67 Ex. 2 PENcoBPDI-5 128 220 257 35 34 0.47 Ex. 3 PENcoBPDI-10 134 227 270 32 31 0.41 Ex. 4 PENcoBPDI-15 140 234 278 33 32 0.61 Ex. 5 PENcoBPDI-20 143 N/A 286 26 25 0.61 Ex. 6 PENcoBPDI-25 147 N/A 287, 314 44 43 0.54

The control sample is pure PEN, synthesised in accordance with the procedure described for Example 2 but without the inclusion of N,N′-bis-(2-hydroxyethyl)-4,4′-biphthalimide.

The polymers of Examples 2, 3 and 5 above were then each melt-pressed to form a thin, tough film (approx. 0.5 mm thick; approx. 2-3 mm wide and approx. 2 cm long) which could be oriented by hot-drawing to at least six times its original extension. Examples 2 and 5 were also cast on a glass slide as solutions in hexafluoroisopropanol (HFIP) at 10% w/w which, after evaporation, produced a strong and flexible film.

Examples 7 and 8

Copolymers comprising 6 mol % (Ex. 7) or 10 mol % (Ex. 8) of monomer were manufactured on a larger scale (using a 5 gallon reactor) using the synthetic methods described above, then dried overnight (8 hours at 150° C.), and biaxially oriented films manufactured therefrom. A 100% PEN film was also prepared as a control.

The polymers were fed to an extruder (single screw; screw speed approx. 80 rpm) at a temperature in the range of 275 to 300° C. depending on the copolymer. A cast film was produced, which was electrostatically pinned and threaded around the casting drum and over the top of the forward draw onto a scrap winder. Once settled, cast samples are collected at a range of casting drum speeds (2, 3 and 5 m\min) to give a range of thicknesses. The cast films are subsequently drawn using a Long Stretcher (available from T.M. Long Co., Somerville, N.J.). The Long Sretcher comprises a hydraulically operated stretching head mounted inside a heated oven with a liftable lid. The operation of the stretching mechanism is based upon the relative motion of two pairs of draw bars (one fixed and one moveable, mounted normally to one another). The draw bars are attached to hydraulic rams which control the amount (draw ratio) and speed (draw rate) of the imposed stretching. On each draw bar are mounted pneumatic sample clips attached to a pantograph system. A sample loading system is used to position samples within the pneumatic clips. A cast sample cut to a specific size (either 7.1×7.1 cm or 11.1×11.1 cm) is located symmetrically on a vacuum plate attached to the end of an arm. The arm is run into the oven and the sample lowered so that it is between the clips. The clips are closed using nitrogen pressure to hold the film and the loading arm withdrawn. The oven is heated to 150° C. by two plate-heaters. The lid is lowered and air heaters rapidly bring the sample up to a specified temperature (typically 160 to 170° C.). After a suitable preheat time (30-60 seconds), the draw is manually initiated by the operator. Draw rates in the approximate range of 2.5-500 mm/second and draw ratios of up to 7× are achievable using this equipment. Simultaneous biaxial draw in perpendicular directions is used in these examples unless otherwise indicated.

The films produced on the Long Stretcher are then crystallised using the Laboratory Crystallisation Rig and held at specified temperatures for specified times. In this equipment, samples are clamped in a frame which is dropped pneumatically and held between heated platens for a specific time before being rapidly quenched by dropping into iced water.

The density of the film samples was measured using a calibrated calcium nitrate/water density column. Crystallinity of all film samples was calculated using known values for PEN density and crystallinity, on the basis of the following literature data:

Density of 0% crystallinity PEN=1.325 g/cm³

Density of 100% crystallinity PEN=1.407 g/cm³

The density and crystallinity results for the films are shown in Tables 2, 3 and 4 below.

TABLE 2 PEN control film Sample Crystallisation conditions Density % Crystallinity A  2 s @ 220° C. 1.360 42.67 B  10 s @ 220° C. 1.361 43.82 C 100 s @ 220° C. 1.362 45.35 J   2 s @ 220° C.* 1.361 43.43 D  2 s @ 230° C. 1.363 45.74 E  10 s @ 230° C. 1.362 45.60 F 100 s @ 230° C. 1.366 49.37 G  2 s @ 240° C. 1.362 44.82 H  10 s @ 240° C. 1.362 45.21 I 100 s @ 240° C. 1.361 43.32 *Manufactured as described above except using sequential draw

TABLE 3 PENcoBPDI-6 film (Example 7) Sample Crystallisation conditions Density % Crystallinity K  2 s @ 220° C. 1.356 38.25 L  10 s @ 220° C. 1.358 40.23 M 100 s @ 220° C. 1.360 42.34 T   2 s @ 220° C.* 1.357 39.24 N  2 s @ 230° C. 1.355 37.01 O  10 s @ 230° C. 1.358 40.71 P 100 s @ 230° C. 1.359 41.57 Q  2 s @ 240° C. 1.357 39.06 R  10 s @ 240° C. 1.358 40.59 S 100 s @ 240° C. 1.357 38.50 *Manufactured as described above except using sequential draw

TABLE 4 PENcoBPDI-10 film (Example 8) Sample Crystallisation conditions Density % Crystallinity U  2 s @ 220° C. 1.364 47.37 V  10 s @ 220° C. 1.363 46.61 W 100 s @ 220° C. 1.364 47.57 DD   2 s @ 220° C.* 1.363 46.87 X  2 s @ 230° C. 1.363 46.16 Y  10 s @ 230° C. 1.361 44.22 Z 100 s @ 230° C. 1.364 47.50 AA  2 s @ 240° C. 1.359 41.12 BB  10 s @ 240° C. 1.361 44.04 CC 100 s @ 240° C. 1.362 44.64 EE  10 s @ 220° C.* 1.363 46.87 *Manufactured as described above except using sequential draw

The data in the tables above demonstrate that the copolymers of the present invention can be manufactured into crystalline biaxially oriented films under typical stenter conditions used on a conventional film-line, and that films manufactured in this way exhibit excellent crystallinity.

Examples 9 and 10

Films corresponding to Examples 7 and 8 above were also produced on a conventional stenter line, wherein biaxially drawn and crystallised film is produced in-line. The temperature of the forward-draw rolls are set at 10 to 15° C. above Tg, with forward draw ratios in the range of 2.8 to 3.3. The drawn film is then threaded through to the stenter under the following conditions:

Stenter preheat temp.: 120° C.

Sideways draw temp.: 130° C.

Crystalliser 1 temp.: 225° C.

Crystalliser 2 temp.: 220° C.

Sideways draw ratio: 3 to 3.3×

The biaxially oriented films produced by the stenter method were stable and exhibited excellent crystallinity. 

1. A copolyester comprising repeating units derived from an aliphatic glycol, naphthalene-dicarboxylic acid, and the monomer of formula (I):

wherein n=2, 3 or 4, and wherein comonomer (I) constitutes a proportion of the glycol fraction of the copolyester.
 2. The copolyester according to claim 1 which has formula (II):

wherein: n=2, 3 or 4; the group X is the carbon chain of said aliphatic glycol; and p and q are the molar fractions of the aliphatic glycol-containing repeating ester units and the monomer (I)-containing repeating ester units, respectively.
 3. The copolyester according to claim 1, wherein the monomer (I) is present in a range of from about 5 to about 50 mol % of the glycol fraction of the copolyester.
 4. The copolyester according to claim 1, wherein the monomer (I) is present at a level of at least about 8 mol % of the glycol fraction of the copolyester.
 5. The copolyester according to claim 1, wherein the naphthalene dicarboxylic acid is 2,6-naphthalene dicarboxylic acid.
 6. The copolyester according to claim 1, wherein the aliphatic glycol is selected from C₂, C₃ and C₄ aliphatic diols.
 7. The copolyester according to claim 1, wherein the aliphatic glycol is ethylene glycol.
 8. The copolyester according to claim 1, wherein the number of carbon atoms in the aliphatic glycol is the same as the number (n) in comonomer (I).
 9. The copolyester according to claim 1, wherein n=2.
 10. (canceled)
 11. A polyester film comprising a copolyester according to claim
 1. 12. A fibre or moulding composition or moulded article comprising a copolyester according to claim
 1. 13. The polyester film according to claim 11, wherein the film is oriented.
 14. The polyester film according to claim 11, wherein the film is biaxially oriented. 